Shingles with a thick appearance

ABSTRACT

A shingle comprises an overlay, an underlay, and a height increasing material disposed between the overlay and the underlay. The height increasing material includes a first adhesive adhered to the overlay, height increasing granules adhered to the first adhesive, and a second adhesive adhered to the height increasing granules and the underlay. The height increasing material can extend along front ends of tab portions of the overlay, along front cutout edges that extend between tab portions of the overlay, or both.

RELATED APPLICATIONS

This patent application is a continuation of U.S. patent applicationSer. No. 16/209,386, filed on Dec. 4, 2018, which claims the benefit ofU.S. Provisional Patent Application Ser. No. 62/594,850, filed on Dec.5, 2017, and of U.S. Provisional Patent Application Ser. No. 62/655,910,filed on Apr. 11, 2018, all of which are incorporated herein byreference in their entireties.

TECHNICAL FIELD

The present invention relates generally to roof shingles for protectinga roof of a structure, and more particularly, shingles having a thickappearance.

BACKGROUND OF THE INVENTION

Many structures have pitched, shingled roofs, which prevent water, e.g.,rain water, from entering the structures by causing water to pass overthe shingles and shed off the roofs. A pitched, shingled roof has apitched substrate, such as a plurality of plywood sheets, with aplurality of shingles attached thereto.

Each shingle has an upper portion (i.e., a headlap portion) and a lowerportion (i.e., an exposure portion) wherein the exposure portion isexposed to the environment. The shingles are typically attached to thesubstrate in rows known as courses wherein the exposure portion of anupper course of shingles overlaps the headlap portion of an adjacentlower course of shingles. For example, a first course of shingles may beattached to the substrate nearest the lowest point of the roof, i.e.,the eave portion of the roof. A second course of shingles may then beattached to the substrate slightly higher on the roof than the firstcourse. The shingles are placed so that the exposure portion of thesecond course of shingles overlaps the headlap portion of the firstcourse of shingles. This overlapping continues with successive rows ofshingles to the highest point on the area of the roof, i.e., the hip orthe ridge.

Hip and ridge shingles are applied along a hip or ridge of a roof (i.e.,transverse to the courses of shingles). These hip and ridge shinglesspan a gap or intersection between courses of shingles of roof planesthat meet at a hip or ridge. These hip and ridge shingles are typicallyapplied along the hip or ridge in a similar fashion, with the exposureportion of one hip and ridge shingle covering the headlap portion of anadjacent shingle on the hip or ridge. Thus, only the exposure portion ofthe shingles are exposed to the environment. This overlapping of theshingles causes water to pass from shingles on higher courses toshingles on the next lowest course of shingles without contacting thesubstrate. Accordingly, water passes from shingle to shingle and off theroof without contacting the substrate or entering the structure.

Attaching the shingles to the roof is typically achieved using nails orother fastening devices that pass through the shingles and into orthrough the substrate. The fastening devices are typically placedthrough the headlap portion of the shingles so that they are overlappedby shingles in an adjacent higher course as described above. Thisplacement of the fasteners prevents water from entering the structurethrough holes caused by the fasteners.

Some roofs have a membrane (i.e., an underlayment) located between thesubstrate and the shingles. The membrane may, as an example, beconventional tar paper or other underlayment material that is nailed tothe substrate. Strips of the membrane are typically attached to the roofin an overlapping fashion wherein an upper strip overlaps its adjacentlower strip. Accordingly, the membrane serves to shield the substratefrom water should a shingle become damaged. For example, if a shinglebecomes cracked or otherwise leaks, water will contact the membranerather than the substrate. Water will then pass along the membranewithout contacting the substrate or entering the structure.

SUMMARY

The present application discloses several embodiments of shingles havingthickened portions. In one exemplary embodiment, a shingle comprises anoverlay, an underlay, and a height increasing material disposed betweenthe overlay and the underlay. The height increasing material can includea first adhesive adhered to the overlay, height increasing granulesadhered to the first adhesive, and a second adhesive adhered to theheight increasing granules and the underlay. The height increasingmaterial can extend along front ends of tab portions of the overlay,along front cutout edges that extend between tab portions of theoverlay, or both.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other features and advantages of the present invention willbecome better understood with regard to the following description andaccompanying drawings in which:

FIG. 1 is a perspective diagram of a roof of a residential home;

FIGS. 2-5 are perspective views of an exemplary hip and ridge shinglebeing folded from an unfolded to folded condition;

FIGS. 6-11 illustrate the steps to install exemplary hip and ridgeshingles on the hip or ridge of a roof;

FIGS. 6A-11A illustrate the steps to install exemplary hip and ridgeshingles on the hip or ridge of a roof;

FIG. 12 shows a perspective view of exemplary hip and ridge shinglesinstalled on the ridge of a roof;

FIG. 13 shows a plan view of an overlay layer of an exemplary laminatedshingle having a folded portion;

FIG. 14 shows a perspective view of exemplary laminated shingle having afolded portion of an overlay layer;

FIG. 15 shows a perspective view of an exemplary laminated shinglehaving a folded portion of an underlay layer;

FIG. 16 shows a perspective view of an exemplary laminated shinglehaving both a folded portion of an overlay layer and folded portion ofan underlay layer;

FIG. 17 shows a perspective view of exemplary laminated shingle havingan intermediate layer;

FIG. 18 shows a side view of exemplary laminated shingle having anintermediate layer;

FIG. 19 shows a perspective view of exemplary laminated shingle havingan intermediate layer;

FIG. 20 shows a perspective view of exemplary laminated shingle havingan intermediate layer;

FIG. 21 shows a perspective view of exemplary laminated shingle havingan intermediate layer with a folded portion;

FIG. 22 shows a side view of exemplary laminated shingle having anintermediate layer with a folded portion;

FIG. 23 shows a perspective view of exemplary laminated shingle havingan intermediate layer with folded portions;

FIGS. 24-27 are perspective views of an exemplary hip and ridge shinglebeing folded from an unfolded to folded condition;

FIG. 28 shows a perspective view of exemplary laminated shingle having adeposited height increasing material;

FIGS. 29A-D show side views of exemplary laminated shingle having adeposited height increasing material in varying stages of construction;

FIG. 30 illustrates a portion of a roof with shingles having a heightincreasing material disposed along front edges of tab portions of theshingles;

FIG. 31 illustrates an exemplary embodiment of an overlay of a shinglehaving a height increasing material applied to rear surface of theoverlay;

FIG. 32 illustrates an exemplary embodiment of an overlay of a shinglehaving a height increasing material applied to rear surface of theoverlay;

FIG. 33 illustrates an exemplary embodiment of an overlay of a shinglehaving a height increasing material applied to rear surface of theoverlay;

FIG. 34 illustrates an exemplary embodiment of an overlay of a shinglehaving a height increasing material applied to rear surface of theoverlay;

FIGS. 35-39 illustrate an exemplary embodiment of manufacturing stagesof a shingle having an overlay, and underlay, and a height increasingmaterial between the overlay and the underlay;

FIGS. 40-44 illustrate an exemplary embodiment of manufacturing stagesof a shingle having an overlay, and underlay, and a height increasingmaterial between the overlay and the underlay;

FIGS. 45-49 illustrate an exemplary embodiment of manufacturing stagesof a shingle having an overlay, and underlay, and a height increasingmaterial between the overlay and the underlay;

FIG. 50 is a flowchart that illustrates an exemplary embodiment of amethod of making shingles with a thickened portion;

FIG. 51 is a flowchart that illustrates an exemplary embodiment of amethod of making shingles with a thickened portion; and

FIGS. 52-58 are perspective views of an exemplary hip and ridge shinglebeing folded from an unfolded to folded condition.

DETAILED DESCRIPTION

Prior to discussing the various embodiments, a review of the definitionsof some exemplary terms used throughout the disclosure is appropriate.Both singular and plural forms of all terms fall within each meaning.

As described herein, when one or more components are described as beingconnected, joined, affixed, coupled, attached, or otherwiseinterconnected, such interconnection may be direct as between thecomponents or may be indirect such as through the use of one or moreintermediary components. Also as described herein, reference to a“member,” “component,” or “portion” shall not be limited to a singlestructural member, component, or element but can include an assembly ofcomponents, members or elements. Also as described herein, the terms“substantially” and “about” are defined as at least close to (andincludes) a given value or state (preferably within 10% of, morepreferably within 1% of, and most preferably within 0.1% of).

Various shingles are disclosed herein that have a thickened appearance,particularly when installed on a roof. The thickened appearance of theshingles is created by adding partial layers of shingle material to theshingle in particular locations and/or by folding at least one portionof the shingle to cause it to appear thicker along the visible portionsof the shingle. As a result, the shingle has a thickened appearancewithout the increased cost of full layers of shingle material.

A shingle configured for folding includes a folded portion that isfolded underneath the shingle or layer of a shingle along a fold line.The folded portion can be formed by extending the length of a tab,underlay, overlay, or any other portion of a shingle beyond the typicallength of such a feature, or beyond other portions of the shingle, sothat when the folded portion is folded, the total length of the shingleis the same as a similar shingle that does not include an extendedportion for folding. Folding a portion of a shingle or a portion of alayer of a laminated shingle creates at least a portion of the shinglehaving a greater thickness. The shingle thus appears to be thickerwithout adding additional layers to the entirety of the shingle. Thus, athicker—and to some, a more aesthetically appealing—appearance isachieved with minimal increase to the cost of the shingle. For example,the folded portion of the shingle may be about 5 percent to about 50percent, or about 10 percent to about 40 percent, or about 20 percent toabout 30 percent of the length of the unfolded portion of the shingle.The folded portion of a folding shingle may be folded duringinstallation of the shingle on a roof and/or may be folded duringmanufacturing. Folding shingles may be configured for use on any portionof a roof, including flat surfaces of the roof and where roof surfacesmeet at an angle—e.g., a hip or a ridge.

As mentioned above, a folding shingle may be folded before the shingleis attached to the roof. For example, the folded portion may be foldedby a worker on the job site or may be folded during manufacturing. Thefolded shingle can be installed on the roof like any other shingle,being nailed in a headlap portion that is overlapped by adjacentshingles in a higher course. Alternatively, the folded portion may benailed to the roof before the rest of the shingle is folded over theaffixed folded portion. The remainder of the shingle may then be naileddown, if desired. Mechanically fastening the folded portion of theshingle to the roof (e.g., with nails) attaches the leading edge of theshingle to the roof, which provides resistance to lifting that can occurwhen the roof is exposed to high winds. Adhesives may also be applied tothe surface of the folding portion that is exposed to the roof to helpsecure the leading edge to the roof.

A variety of materials may be used to form the folding shingle, such as,for example, a substrate such as a glass fiber mat or an organic felt,an asphalt and/or non-asphalt coating on the substrate, and a surfacelayer of granules embedded in the asphalt coating. The shingle materialmay be stiff or difficult to bend or may be susceptible to cracking ortearing when bent. Thus, in some embodiments, the fold line includes aline of perforations or cuts or is partially cut to reduce the thicknessof the shingle along the fold line to enable or facilitate bending ofthe shingle material. Once bent, the fold area along the fold line maybe weakened and may partially tear or crack without completely breaking.Thus, a reinforcing material may be applied to the fold area to reducecracking or tearing of the shingle material during folding, and toprohibit the spread of any cracks or tears that happen to form in thematerial during bending.

Referring now to FIG. 1, a diagram of a roof structure 100 is shown. Theroof 100 is a shingled roof, covered with individual shingles 102. Thesides of the roof 100 come together to form a ridge 104 at the top ofthe roof 100. Hips 106 are formed when an inclined roof plane 108 meetsthe sides of the roof, instead of a gable end. The hips 106 extend fromthe eaves of the roof to the ridge 104. The roof 100 also has a leadingedge 114 at a lower edge of each side. The shingles 102 of the roof 100are applied in courses on top of an optional underlayment (not shown)and sheeting and/or decking (not shown). The shingles 102 may besingle-layer three-tab shingles, or may be laminate shingles, such asthe shingles described in U.S. Pat. Nos. 8,430,983 and 9,121,178, whichare incorporated herein by reference in their entirety.

Referring now to FIGS. 2-5, an exemplary folding shingle 200 for use ona roof hip or ridge is shown. A rear or back surface 202 is shown facingupwards in FIG. 2 with the shingle 200 in an unfolded condition, and afront or exposed surface 208 is revealed in FIGS. 3-5 as the shingle 200is folded into a folded condition shown in FIG. 5. The shingle 200 has afolded portion 201 and a main body or unfolded portion 203 and isfoldable along a folding line 204. The folded portion 201 of the shinglemay be about 5 percent to about 50 percent, or about 10 percent to about40 percent, or about 20 percent to about 30 percent of the length of theunfolded portion 203 of the shingle. The shingle 200 extends from abottom edge 205 to a top edge 207. The shingle 200 may be attached tothe roof 100 by any suitable means, such as, for example, adhesive,nails, screws, staples, sealant, or other fastening devices. In someembodiments, a nail zone 206 on the rear surface of the folded portion201 reinforces the material of the shingle to prohibit pull-through ofnails used to secure the shingle 200 to the roof. The nail zone 206 mayoptionally be reinforced with reinforcement tape or any other materialsuitable for improving the strength of the shingle to resist nail pullthrough. The exposed surface 208 optionally includes an adhesive portion210 arrange near or proximate the top edge 207 for adhering to shinglesof an adjacent higher course after the shingle 200 is installed andfolded.

The shingle 200 is secured to the roof with nails hammered through thenail zone 206 of the folded portion 201. The unfolded portion 203 isthen lifted upward and folded back along the fold line 204 until theunfolded portion 203 contacts the folded portion 201. Additional nailsmay then be used to secure the unfolded portion 203 to the roof in anoptional nail zone (not shown). A shingle for the next course can thenbe installed on top of the shingle 200 in the same way. The shingle 200may optionally include an alignment line on the exposed surface 208 ofthe unfolded portion 203 to aid in aligning the next course of shingles.

FIGS. 6-11 illustrate the steps to install exemplary folding hip andridge shingles 200 on the hip or ridge 104, 106 of a roof 100. Referringnow to FIG. 6, an optional starter shingle 230 is shown. The startershingle 230 may or may not include a folded portion to provide a thickerappearance to a leading edge 212. The leading edge 212 corresponds tothe bottom portion of the shingle 200, 230 which is visible by a personviewing the roof 100 from ground level. In the illustrated embodiment,the leading edge 212 of the starter shingle 230 is aligned with theleading edge 114 of the roof 100. The starter shingle 230 and shingles200 may be attached to the roof 100 by any suitable means, such as, forexample, adhesive, nails, screws, staples, sealant, and/or otherfastening devices. When mechanical fasteners are used, they may be withthe shingle 200 being nailed on the left 110 and right 112 sides of thehip or ridge 104, 106.

Referring to FIG. 7, in some embodiments, a nail zone 206 on the rearsurface of the folded portion 201 reinforces the material of the shingleto prohibit pull-through of nails used to secure the shingle 200 to theroof. In some embodiments, a ridge vent (not shown) is installed betweenthe hip and ridge shingle 200 and the roof 100. The starter shingle 230includes an adhesive portion 210 on the exposed surface 208 to helpsecure subsequently installed shingles.

Referring now to FIG. 7, the first course folding shingle 200 is nailedto the roof 100 in the unfolded condition. The nails 220 are applied inthe nail zone 206 of the folded portion 201 on one side—the right side112 in FIG. 7—of the hip or ridge 104, 106. The nails 220 are onlyapplied on one side so that the shingle 200 can be folded along the foldline 204. That is, if the shingle was nailed on both sides it would befolded convexly over the hip or ridge 104, 106, thereby making itdifficult to fold the shingle along the fold line 204 without tearing.In some embodiments, however, the fold line may include cuts,perforations, or lines of weakness that allow the shingle to be foldedwith both sides nailed down. The unfolded portion 203 of the shingle 200is folded up to meet the roof, thereby creating a thicker leading edge212 and the exposed surface 208 faces outward, as shown in FIG. 8. Theunfolded portion 203 in in contact with the roof and can be optionallynailed down as well, on one or both sides 110, 112 of the hip or ridge104, 106.

The steps shown in FIGS. 7 and 8 are repeated with the second course offolding shingles 200, as shown in FIGS. 9 and 10. The shingles of thesecond course, however, are nailed on the left side 110 of the hip orridge 104, 106. The nails 220 in the second course penetrate the firstcourse as well, thereby securing both sides of the first course shingle.Shingles of additional courses are then applied in a similar manneruntil the hip or ridge 104, 106 is covered in shingles 200, as can beseen in FIG. 11. During installation of additional courses, the nails220 are applied to alternating sides 110, 112 of the hip or ridge 104,106.

Referring now to FIG. 12, a perspective view of exemplary hip and ridge200 shingles installed on the ridge 104 of a gabled roof following thesteps illustrated in FIGS. 6-11. The folded portions 201 of the shingles200 can be seen folded under the unfolded portions 203, thus providingthe thicker appearance of the leading edge 212 than would otherwise beprovided by non-folding shingles.

Similar concepts shown above in FIGS. 2-12 may also be applied toshingles used on the flat surfaces 108 of a roof 100, which in someembodiments may be laminated shingles having overlay and underlaylayers. One or both of these layers may include a folded portion. Such afolded portion may be folded during manufacturing of the shingles, orduring installation.

Referring now to FIGS. 13-16, exemplary laminated folding shingles areshown. Referring now to FIGS. 13-14, exemplary laminated foldingshingles 300 are shown having a folding overlay layer. The shingles havean overlay layer 302 attached to an underlay layer 318 using an adhesiveor any other suitable attachment means, which may or may not extend thefull height of the overlay layer 302. The overlay layer 302 has a frontsurface 301, a rear surface 303, a headlap portion 304, and a tabportion 306 having a plurality of tabs 307. The overlay layer 302includes a folded portion 310 and an unfolded portion 312, the foldedportion being folded along a fold line 308 so that it is arrangedbetween the underlay layer 318 and the unfolded portion 312 of theoverlay layer 302. The folded portion 310 of the shingle may be about 5percent to about 50 percent, or about 10 percent to about 40 percent, orabout 20 percent to about 30 percent of the length of the unfoldedportion 312 of the shingle. In some embodiments, adhesive is provided onthe front and/or back surfaces 301, 303 of the folded portion 310 sothat the folded portion 310 adheres to the unfolded portion 312 and theunderlay layer 318 after folding. The shingle 300 may optionally includean alignment guide 314 to assist in aligning adjacent courses ofshingles. The overlay sheet 302 may optionally include a nail zone (notshown) that may optionally be reinforced with reinforcement tape or anyother material suitable for improving the strength of the shingle toresist nail pull through.

Referring now to FIG. 14, a perspective view of the shingle 300 is shownwith the overlay layer 302 attached to the underlay layer 318. Thefolded portion 310 of the tabs 307 of the overlay layer 302 can be seenfolded under the unfolded portion 312, thus providing a thickerappearance of a leading edge 316 of the shingle 300 than would otherwisebe provided by non-folding shingles.

In the example illustrated by FIGS. 13 and 14, the folded portion 310 ofthe tabs will typically be folded under during the manufacturing processand be permanently secured to the underlay layer 302 and the unfoldedportion 312 by an adhesive during the manufacturing process. The shingle300 would be attached to the roof in a conventional manner by fastening,such as nails, driven through a nail zone at the shingle near the line314.

Referring now to FIG. 15, exemplary laminated folding shingles 400 areshown having a folding underlay layer. The shingles 400 have an overlaylayer 402 attached to an underlay layer 418 using an adhesive or anyother suitable attachment means, which may or may not extend the fullheight of the overlay layer 402. The overlay layer 402 has a headlapportion 404, and a tab portion 406 having a plurality of tabs. Theoverlay layer 402 includes a folded portion 410 and an unfolded portion412, the folded portion being foldable along a fold line 408 so that itis arranged between the unfolded portion 412 of the underlay layer 418an adjacent shingle. The folded portion 410 of the underlay layer 402can be seen folded under the unfolded portion 412, thus providing athicker appearance of a leading edge 416 of the shingle 400 than wouldotherwise be provided by non-folding shingles. The folded portion 410 ofthe shingle may be about 5 percent to about 50 percent, or about 10percent to about 40 percent, or about 20 percent to about 30 percent ofthe length of the unfolded portion 412 of the shingle. In someembodiments, adhesive is provided on the front and/or back surfaces ofthe folded portion 410 so that the folded portion 410 adheres to theunfolded portion 412 and/or an adjacent shingle after folding. Theshingle 400 may optionally include an alignment guide 414 to assist inaligning adjacent courses of shingles. The overlay sheet 402 mayoptionally include a nail zone (not shown) that may optionally bereinforced with reinforcement tape or any other material suitable forimproving the strength of the shingle to resist nail pull through.

In the example illustrated by FIG. 15, the folded portion 410 of thetabs can be folded under during the manufacturing process of duringinstallation. When the folded portion 410 is folded and secured to theunfolded portion 412 during the manufacturing process, the shingle wouldbe attached to the roof in a conventional manner by fasteners, such asnails driven through a nail zone at or near the line 414. In the exampleillustrated by FIG. 15, when the folded portion 410 is folded duringinstallation, the shingles can be installed in generally the same manneras illustrated by FIGS. 6-11. However, since the shingles 400 areinstalled on a flat surface, nails or other fasteners are driven throughthe folding portion 410 along the entire length of the folding portion.

Referring now to FIG. 16, an exemplary embodiment of a shingle 500 isshown that combines the features of the embodiment of FIG. 14 and theembodiment of FIG. 15. That is, the shingle 500 illustrated by FIG. 16has both a folded overlay portion 510 and a folded underlay portion 518.The shingles 500 have an overlay layer 502 attached to an underlay layer508 using an adhesive or any other suitable attachment means, which mayor may not extend the full height of the overlay layer 502. The overlaylayer 502 has a headlap portion 504, and a tab portion 506 having aplurality of tabs. The overlay layer 502 includes the folded overlayportion 510 and an unfolded overlay portion 512, the folded portion 510being foldable along a fold line so that folded portion 510 is arrangedbetween the underlay layer 508 and the unfolded portion 512 of theoverlay layer 502. The underlay layer 508 includes a folded underlayportion 518 and an unfolded underlay portion 520, the folded portion 518being foldable along a fold line so that it is arranged between theoverlay layer 502 of an adjacent shingle and the unfolded portion 520 ofthe underlay layer 508. The folded portions 510, 518 can be seen foldedunder the unfolded portions 512, 520, thus providing a thickerappearance of a leading edge 516 of the shingle 400 than would otherwisebe provided by non-folding shingles. The folded portions 510, 518 of theshingle 500 may be the same length or different lengths, and may beabout 5 percent to about 50 percent, or about 10 percent to about 40percent, or about 20 percent to about 30 percent of the length of theunfolded portions 512, 520 of the shingle 500. In some embodiments,adhesive is provided on the front and/or back surfaces of the foldedportions 510, 518 so that the folded portions 510, 518 adheres to theunfolded portions 512, 520 and/or an adjacent shingle after folding. Theshingle 500 may optionally include an alignment guide 514 to assist inaligning adjacent courses of shingles. The overlay sheet 502 mayoptionally include a nail zone (not shown) that may optionally bereinforced with reinforcement tape or any other material suitable forimproving the strength of the shingle to resist nail pull through. Theshingle 500 can be installed in the same manner that the shingles 400illustrated by FIG. 15 can be installed; i.e., in a conventional manneror by folding during installation as illustrated by FIGS. 6-11.

Referring now to FIGS. 17-23, exemplary laminated shingles with athicker appearance are shown. The exemplary shingles of FIGS. 17-23include an intermediate layer or strip between the underlay and overlayto provide a thicker appearance that may be formed from a separate pieceof material or a folded portion of a layer of the shingles. The shinglesare shown in perspective views, with side views shown of someembodiments (e.g., FIGS. 18, 22). When shown in the side view, thelayers are shown in the abstract where the tab portions are spaced apartfrom the underlay layer, though these layers would bend to contact eachother when the shingles are made, and a gap would not exist along theentire length of the tabs.

Referring now to FIGS. 17 and 18, exemplary laminated shingles 600 areshown having an intermediate layer 610. The shingles have an overlaylayer 602 attached to an underlay layer 608 using an adhesive or anyother suitable attachment means, which may or may not extend the fullheight of the overlay layer 602. The overlay layer 602 has a headlapportion 604, and a tab portion 606 having a plurality of tabs. Anintermediate layer 610 is provided between the overlay and underlaylayers 602, 608. The intermediate layer 610 is arranged between theheadlap portion 604 of the overlay layer 602 and the underlay layer 608and does not substantially extend under the tab portion 606. As can beseen in FIG. 18, an adhesive 616 attaches the layers 602, 608, 610together. The intermediate layer 610 is formed from a strip of materialthat extends from the top of the tab cutouts to an upper end of theunderlay layer 606 for the full width of the shingle 600. In certainembodiments, the intermediate layer 610 extends under the entire widthof the headlap portion 604 of the overlay layer 602. The intermediatelayer 610 under the headlap portion 602 increases the thickness of theshingle 600 to create a thickened portion 612 at the top of the openingsbetween tabs of the tabbed portion 606. The shingle 600 may optionallyinclude an alignment guide 614 to assist in aligning adjacent courses ofshingles. In one exemplary embodiment, the intermediate layer 610 canextend to the alignment guide 614. The overlay sheet 602 may optionallyinclude a nail zone (not shown) that may optionally be reinforced withreinforcement tape or any other material suitable for improving thestrength of the shingle to resist nail pull through. In one exemplaryembodiment, the intermediate layer can extend under all or a portion ofthe nail zone.

Referring now to FIG. 19, exemplary laminated shingles 700 are shownhaving an intermediate layer 710. The shingles have an overlay layer 702attached to an underlay layer 708 using an adhesive or any othersuitable attachment means, which may or may not extend the full heightof the overlay layer 702. The overlay layer 702 has a headlap portion704, and a tab portion 706 having a plurality of tabs. The intermediatelayer 710 is provided between the overlay and underlay layers 702, 708.The intermediate layer 710 is arranged between the headlap portion 704of the overlay layer 702 and the underlay layer 708 and does notsubstantially extend under the tab portion 706. The intermediate layer710 is formed from a strip of material that extends from the top of thetab cutouts to an upper end of the underlay layer 706 for the full widthof the shingle 700. In certain other embodiments, the intermediate layer710 extends under the entirety of the headlap portion 704 of the overlaylayer 702. A bottom edge layer 712 is attached to the bottom of theunderlay layer 708. The bottom edge layer 712 is formed from a strip ofmaterial that extends for the full width of the shingle 700 along thebottom edge of the underlay layer 708. In certain embodiments, thebottom edge layer 712 extends underneath the entirety of the underlaylayer 708. The intermediate layer 710 and/or the bottom edge layer 712can be from 0.5 to 2.0 inches wide, however, other widths are possible.The intermediate layer 710 and the bottom edge layer 712 increase thethickness of the shingle to create a first thickened portion 714 at thetop of the openings between tabs of the tabbed portion 706 and a secondthickened portion 716 at the bottom edge of the shingle 700. The shingle700 may optionally include an alignment guide 718 to assist in aligningadjacent courses of shingles. The intermediate layer 710 can extend tothe alignment guide 718. The overlay sheet 702 may optionally include anail zone (not shown) that may optionally be reinforced withreinforcement tape or any other material suitable for improving thestrength of the shingle to resist nail pull through. The intermediatelayer 710 can extend under all or a portion of the nail zone.

Referring now to FIG. 20, exemplary laminated shingles 800 are shownhaving an intermediate layer. The shingles have an overlay layer 802attached to an underlay layer 808 using an adhesive or any othersuitable attachment means, which may or may not extend the full heightof the overlay layer 802. The overlay layer 802 has a headlap portion804, and a tab portion 806 having a plurality of tabs. An intermediatelayer 810 is provided between the overlay and underlay layers 802, 808.The intermediate layer 810 is arranged between the headlap portion 804of the overlay layer 802 and the underlay layer 808 and substantiallymatches the size and shape of the tab portion 806. The intermediatelayer 810 extends underneath the tabs of the tab portion 806 from thebottom edge of the shingle to the upper edge of the underlay layer 808.In certain other embodiments, the intermediate layer 810 can extendunder the entirety of the headlap portion 804 of the overlay layer 802.A bottom edge layer 812 is attached to the bottom of the underlay layer808. The bottom edge layer 812 is formed from a strip of material thatextends for the full width of the shingle 800 along the bottom edge ofthe underlay layer 808. In certain other embodiments, the bottom edgelayer 812 can extend underneath the entirety of the underlay layer 808.The intermediate layer 810 and the bottom edge layer 812 increase thethickness of the shingle to create a first thickened portion 814 at thetop of the openings between tabs of the tabbed portion 806 and a secondthickened portion 816 at the bottom edge of the shingle 800, which isthicker than the second thickened portion 716 of shingle 700. Theshingle 800 may optionally include an alignment guide 818 to assist inaligning adjacent courses of shingles. In one exemplary embodiment, theintermediate layer 810 can extend to the alignment guide 818. Theoverlay sheet 802 may optionally include a nail zone (not shown) thatmay optionally be reinforced with reinforcement tape or any othermaterial suitable for improving the strength of the shingle to resistnail pull through. In one exemplary embodiment, the intermediate layer810 can extend under all or a portion of the nail zone.

Referring now to FIGS. 21 and 22, exemplary laminated shingles 900 areshown having an intermediate folded layer 910. The shingles have anoverlay layer 902 attached to an underlay layer 908 using an adhesive orany other suitable attachment means, which may or may not extend thefull height of the overlay layer 902. The overlay layer 902 has aheadlap portion 904, and a tab portion 906 having a plurality of tabs.The underlay layer 908 includes a folded portion 910 and an unfoldedportion 912, the folded portion 910 being folded along a fold line sothat the folded portion 910 is arranged between the overlay layer 902and the unfolded portion 912 of the underlay layer 902, thus forming anadditional layer of material, or intermediate layer, between the overlaylayer 902 and underlay layer 908. The folded portion 910 can be foldedduring manufacturing before the overlay and underlay layers 902, 908 arejoined together. The folded portion 910 and the unfolded portion 912 canbe connected together by a tape or scrim, so that the folded portion 910remains connected to the unfolded portion 912 after the folded portion910 is folded. Any folded portions and unfolded portions described inthis application can be connected together by tape, scrim, or othermaterial. The folded portion 910 extends from the fold to the tabcutouts of the tab portion 906. In certain other embodiments, the foldedportion 910 can extend under the entirety of the tab portion 906, likethe intermediate layer 810 of shingle 800 as shown in FIG. 20. Thefolded portion 910 may be about 5 percent to about 50 percent, or about10 percent to about 40 percent, or about 20 percent to about 30 percentof the length of the unfolded portion 912 of the underlay layer 908. Thefolded portion can be between 0.5 and 2.0 inches wide. As can be seen inFIG. 22, an adhesive 918 attaches the layers 902 and 908 together. Theadhesive 918 also attaches the folded portion 910 to the unfoldedportion 912.

The folded portion or intermediate layer 910 under the headlap portion902 increases the thickness of the shingle 900 to create a thickenedportion 914 at the top of the openings between tabs of the tabbedportion 906. The shingle 900 may optionally include an alignment guide916 to assist in aligning adjacent courses of shingles. In one exemplaryembodiment, the folded portion 910 extends to the alignment guide 916.The overlay sheet 902 may optionally include a nail zone (not shown)that may optionally be reinforced with reinforcement tape or any othermaterial suitable for improving the strength of the shingle to resistnail pull through. In one exemplary embodiment, the folded portion 910extends under all or a portion of the nail zone.

Referring now to FIG. 23, exemplary laminated shingles 1000 are shownhaving an intermediate folded layer 1010. The shingles 1000 have anoverlay layer 1002 attached to an underlay layer 1008 using an adhesiveor any other suitable attachment means, which may or may not extend thefull height of the overlay layer 1002. The overlay layer 1002 has aheadlap portion 1004, and a tab portion 1006 having a plurality of tabs.The underlay layer 1008 includes a first folded portion 1010, anunfolded portion 1012, and a second folded portion 1014. The firstfolded portion 1010 can be connected to the first unfolded portion 1012by a tape or scrim. The tape or scrim prevents the first folded portion1010 from disconnecting from the first unfolded portion 1012 whenfolded. The second folded portion 1014 can be connected to the firstunfolded portion 1012 by a tape or scrim. The tape or scrim prevents thesecond folded portion 1014 from disconnecting from the first unfoldedportion 1012 when folded.

The shingle 1000 may optionally include an alignment guide 1020 toassist in aligning adjacent courses of shingles. In one exemplaryembodiment, the first folded portion 1010 extends to the alignmentguide. The overlay sheet 1002 may optionally include a nail zone (notshown) that may optionally be reinforced with reinforcement tape or anyother material suitable for improving the strength of the shingle toresist nail pull through. In one exemplary embodiment, the first foldedportion 1010 extends completely or partially beneath the nail zone. Inone exemplary embodiment, the first folded portion 1010 and/or thesecond folded portion 1014 can be between 0.5 and 2.0 inches wide in oneexemplary embodiment.

The first folded portion 1010 is folded so that the first folded portion1010 is arranged between the overlay layer 1002 and the unfolded portion1012 of the underlay layer 1002, thus forming an additional layer ofmaterial, or intermediate layer, between the overlay layer 1002 andunderlay layer 1008. The first folded portion 1010 extends from the foldto the tab cutouts of the tab portion 1006. In certain embodiments, thefirst folded portion 1010 extends under the entirety of the tab portion1006, like the intermediate layer 810 of shingle 800 as shown in FIG.20. The second folded portion 1014 is folded so that the second foldedportion 1014 is arranged under the unfolded portion 1012 of the underlaylayer 1008. The second folded portion 1014 extends from a fold at thebottom edge of the shingle 1000 underneath the unfolded portion 1012.The first and second folded portions 1010, 1014 are folded duringmanufacturing before the overlay and underlay layers 1002, 1008 arejoined together. The first and second folded portions 1010, 1014 may beabout 5 percent to about 50 percent, or about 10 percent to about 40percent, or about 20 percent to about 30 percent of the length of theunfolded portion 1012 of the underlay layer 1008. The first and secondfolded portions 1010, 1014 may be the same length, or may be differentlengths. In certain embodiments, the second folded portion 1014 extendsunder the entirety of the unfolded portion 1012. Adhesive can optionallyattach the first and second folded portions 1010, 1014 to the unfoldedportion 1012. The first and second folded portions 1010, 1014 increasethe thickness of the shingle 1000 to create a first thickened portion1016 at the top of the openings between tabs of the tabbed portion 1006and a second thickened portion 1018 along the bottom edge of the shingle1000.

Referring now to FIGS. 24-27, an exemplary folding shingle 1100 for useon a roof hip or ridge is shown. A rear or back surface 1102 is shownfacing upwards in FIG. 24 with the shingle 1100 in an unfoldedcondition, and a front or exposed surface 1108 is revealed in FIGS.25-27 as the shingle 1100 is folded into a folded and/or installedcondition shown in FIG. 27. The shingle 1100 has a folded portion 1101and a main body or unfolded portion 1103 and is foldable along a foldingline 1104. The folded portion 1101 of the shingle may be about 5 percentto about 50 percent, or about 10 percent to about 40 percent, or about20 percent to about 30 percent of the length of the unfolded portion1103 of the shingle 1100.

The shingle 1100 extends from a bottom edge 1105 to a top edge 1107. Theshingle 1100 may be attached to the roof 100 by any suitable means, suchas, for example, adhesive, nails, screws, staples, sealant, or otherfastening devices. In some embodiments, a nail zone 1106 on the rearsurface of the folded portion 1101 reinforces the material of theshingle to prohibit pull-through of nails used to secure the shingle1100 to the roof. The nail zone 1106 may optionally be reinforced withreinforcement tape or any other material suitable for improving thestrength of the shingle to resist nail pull through. The exposed surface1108 optionally includes an adhesive portion 1110 arrange near orproximate the top edge 1107 for adhering to shingles of an adjacenthigher course after the shingle 1100 is installed and folded.

The shingle 1100 is secured to the roof with nails hammered through thenail zone 1106 of the folded portion 1101. The unfolded portion 1103 isthen lifted upward and folded back along the fold line 1104 until theunfolded portion 1103 contacts the folded portion 1101. Additional nailsmay then optionally be used to secure the unfolded portion 1103 to theroof in an optional nail zone (not shown). A shingle for the next coursecan then be installed on top of the shingle 1100 in the same way. Theshingle 1100 may optionally include an alignment line on the exposedsurface 1108 of the unfolded portion 1103 to aid in aligning the nextcourse of shingles.

In the example illustrated by FIGS. 24-27, reinforcing material 1114 isapplied to the folding line 1104 to maintain the connection between thefolded and unfolded portions 1101, 1103 in case the shingle materialbreaks along the folding line 1104 after folding or during the life ofthe shingle. An adhesive portion 1116 is provided on the folded portion1101 of the shingle 1100 to secure the folded and unfolded portions1101, 1103 together after folding the shingle. The adhesive portion 1116could be provided on the unfolded portion 1103 on the opposite side ofthe reinforcing material 1114, instead of or in addition to the adhesiveportion 1116 on the folded portion 1101. The adhesive portion 1116 meltsand join the portions 1101, 1103 together as the installed shingle 1100heats up from exposure to the light of the sun. In certain embodiments,the adhesive portion 1116 is applied to the unfolded portion 1103 or maybe applied to both folded and unfolded portions 1101, 1103. Thereinforcing material 1114 and/or an adhesive portion 1116 can be appliedto any of folded portions of the laminated shingles described above.

Referring now to FIGS. 28 and 29A-29D, a further exemplary laminatedshingle 1200 with a thicker appearance is shown. The exemplary shingle1200 of FIGS. 28 and 29A-29D includes a deposited height increasingmaterial 1209. The deposited height increasing material 1209 may take awide variety of different forms. Any material that can be sprayed,extruded, coated, rolled or otherwise dispensed onto the underlay and/oroverlay layers 1202, 1208 can be used. One, two, three or any number ofmaterials can be deposited to form the height increasing layer 1209.Examples of deposited height increasing layers include, but are notlimited to, asphalt, including filled and unfilled asphalt, ceramiccoated roofing granules, crushed rock (i.e., small granule-sized rocks),crushed rock that is not ceramic coated, sealants and adhesives, such asasphalt based sealants and adhesives and non-asphalt based sealants andadhesives, sand, hot melt plastic, etc. and any combination of thesematerials. In one exemplary embodiment, the material(s) used to make thedeposited height increasing layer 1209 are material(s) that are used inconstruction of the other portions of the shingle (i.e., the material(s)is already used in an otherwise identical shingle that does not includethe deposited height increasing layer 1209). For example, the depositedlayer 1209 may include one or more of roofing granules, asphalt coating,backing sand, fiberglass mat, and sealant or adhesive (used to securelayers of the laminated shingle together) that are used in otherportions of the laminated shingle 1200.

The shingle 1200 is shown in a perspective view and with side viewsshown of the shingle in various stages of construction (e.g., FIGS.29A-29D). When shown in the side view, the layers are shown in theabstract where the tab portions are spaced apart from the underlaylayer, though these layers would bend to contact each other when theshingles are made, and a gap may or may not exist along the entirelength of the tabs.

An exemplary laminated shingle 1200 is shown in FIGS. 28 and 29A-29Dhaving a deposited height increasing material 1209 that comprises anintermediate adhesive layer 1210 and intermediate granule coating 1211.The shingles have an overlay layer 1202 attached to an underlay layer1208 using an adhesive or sealant or any other suitable attachmentmeans, which may or may not extend the full height of the overlay layer1202. For example, laminating adhesive may be provided between thelayers 1202, 1208 at one or more of regions 2802, 2804, 2806. Also, thedeposited height increasing material 1209 can be applied at other areasbetween the layers 1202, 1208, such as area 2802. The overlay layer 1202has a headlap portion 1204, and a tab portion 1206 having a plurality oftabs. A deposited height increasing material 1209, such as theillustrated intermediate adhesive layer 1210 and an intermediate granulecoating 1211, is provided between the overlay and underlay layers 1202,1208. The deposited height increasing material 1209 is arranged betweenthe headlap portion 1204 of the overlay layer 1202 and the underlaylayer 1208 and does not substantially extend under the tab portion 1206.In the illustrated example, a front edge 1213 of the deposited heightincreasing material 1209 is aligned with or substantially aligned with acutout edge 1215 of the overlay layer 1202.

In the illustrated embodiment, the intermediate adhesive layer 1210 isdisposed on an upper surface of the underlay layer 1208. Theintermediate granule coating 1211 is disposed between the intermediateadhesive layer 1210 and the overlay layer 1202. As can be seen in FIGS.29C and 29D, an adhesive 1216 attaches the intermediate granule coating1211 and overlay layer 1202, thereby securing the layers 1202, 1208 ofthe shingle 1200 together. However, the layers can be flipped with thelayer 1210 on the overlay layer 1202 and the adhesive 1216 on theunderlay layer 1208.

Turning to FIGS. 29A-29D, a process of forming the exemplary shingle1200 is depicted. The height increasing deposited material 1209 isdeposited on the underlay layer 1206. For example, the intermediateadhesive layer 1210 can be deposited onto a top surface of the underlaylayer 1208 along an upper edge of the underlay layer 1206 for the fullwidth of the shingle 1200. However, in other embodiments, the adhesive1210 can be applied to the bottom of the overlay layer 1202. As such,the intermediate adhesive layer 1210 extends the entire width of theheadlap portion 1204 of the overlay layer 1202. The intermediateadhesive layer 1210 may be any adhesive known in the art. Preferably,the intermediate adhesive layer 1210 is extrusion coated onto the outeredge of the underlay layer 1208. In an additional preferred embodiment,the intermediate adhesive layer 1210 is extrusion coated to a widthbetween about 0.5 and 2.0 inches, such as between about 0.75 and 1.5inches, such as about 1.0 inch. In a further preferred embodiment, theintermediate adhesive layer 1210 is extruded to a height between about0.010 and 0.050 inches, such as between about 0.020 and 0.040 inches,such as about 0.030 inches. In this example, providing a heightincreasing material 1209 at area 2802 provides the front edge of the tabportion 1206 with a thicker appearance. The deposited height increasingmaterial 1209 can be deposited at the area 2806 and area 2802, at thearea 2806 but not the area 2802, and the material 1209 can be applied atthe area 2802 but not the area 2806. In one exemplary embodiment, theheight increasing material 1209 is applied in the area 2802 to increasethe height of the front edges of the tabs, in the are 2806 to increasethe height of the cutout edge 1215, and in the area 2804 (and optionallyadditional areas between the areas 2802, 2806) to provide a consistentthickness to the tabs.

Granules are subsequently applied onto the intermediate adhesive layer1210 to form the intermediate granule coating 1211 (FIG. 29B). Thegranules 1211 may optionally be pressed into the adhesive layer 1210,such that the granules become embedded in the adhesive layer 1210. Thegranules may be the same type of roofing granules used at other parts ofthe shingle 1200. For example, the granules may be the same type ofgranule used in the headlap portion of the shingle 1200.

An adhesive 1216 is disposed on top of the intermediate granule coating1211 (FIG. 29C) or may be applied to the overlay layer 1202, such thatthe adhesive 1216 becomes disposed on the granule coating 1211 when theunderlay layer 1280 is assembled to the overlay layer 1202. The adhesive1216 may be any adhesive or any other suitable attachment means. Theadhesives and/or adhesives 1210, 1216 may be the same material. In oneexemplary embodiment, the adhesives 1216 are the same materials used tolaminate the layers 1202, 1208 of the shingle 1200 together at otherlocations of the shingle 1200. The overlay layer 1202 is then attachedto the adhesive 1216 (FIG. 29D) to form the shingle 1200. The overlaylayer 1202 may be laminated to the remainder of the shingle 1200 in theconventional fashion with lines of adhesive or sealant. The depositedheight increasing material 1209, formed of the intermediate adhesivelayer 1210 and intermediate granule coating 1211, under the headlapportion 1202 increase the thickness of the shingle 1200 to create athickened portion 1212 at the top of the gaps between tabs of the tabbedportion 1206.

The shingle 1200 may optionally include an alignment guide 1214 toassist in aligning adjacent courses of shingles. In one exemplaryembodiment, the intermediate adhesive layer 1210 and intermediategranule coating 1211 can extend to the alignment guide 1214. The overlaysheet 1202 may optionally include a nail zone (not shown) that mayoptionally be reinforced with reinforcement tape or any other materialsuitable for improving the strength of the shingle to resist nail pullthrough. In one exemplary embodiment, the intermediate layer can extendunder all or a portion of the nail zone.

FIG. 30 illustrates an exemplary embodiment of a roof 3000 havingshingles 1200 with height increasing material 1209. In the illustratedexample, the height increasing material 1209 is applied between theoverlay 1202 and the underlay 1280 near the front edges 3002 of the tabportions 1206 and the front edge 3004 of the underlay 1280. Thisconfiguration provides the front edges 3002 of the tab portions 1206 ita thicker or raised appearance. In other exemplary embodiments, theheight increasing material can be provided between the overlay 1202 andthe underlay 1280 near the cutout edge 1215. In other exemplaryembodiments, the height increasing material can be provided between theoverlay 1202 and the underlay 1280 both near the front edges 3002 andnear the cutout edge 1215.

As noted above, the height increasing material 1209 can be applied tothe overlay 1202 and/or the underlay 1280. In the example illustrated byFIG. 31, the height increasing material 1209 is applied to the bottomsurface 3100 of the overlay 1202 at or near the front edges 3002 of thetab portions 1206 before the overlay 1202 is laminated to the underlay1280. In the example illustrated by FIG. 32, the height increasingmaterial 1209 is applied to the bottom surface 3100 of the overlay 1202at or near the cutout edge 1215 before the overlay 1202 is laminated tothe underlay 1280. In the example illustrated by FIG. 33, the heightincreasing material 1209 is applied to the bottom surface 3100 of theoverlay 1202 at or near the front edges 3002 of the tab portions 1206and near the cutout edge 1215 before the overlay 1202 is laminated tothe underlay 1280. In the example illustrated by FIG. 34, the heightincreasing material 1209 is applied to the bottom surface 3100 of theoverlay 1202 at or near the front edges 3002 of the tab portions 1206,near the cutout edge 1215, and between the front edges 3002 and thecutout edge 1215 before the overlay 1202 is laminated to the underlay1280.

FIGS. 35-39 illustrate an exemplary embodiment of a method for making ashingle where a height increasing material 1209 is deposited on thebottom surface 3100 of the underlay layer 1206 near the front edges 3002of the tab portions 1206. Referring to FIG. 35, the intermediateadhesive layer 1210 can be deposited onto the bottom surface 3100 of theunderlay layer 1206 near the front edges 3002 of the tab portions 1206.As such, the intermediate adhesive layer 1210 extends only along thewidths of the front edges of the tab portions 1206 (See FIG. 31). Theintermediate adhesive layer 1210 may be any adhesive known in the art.The intermediate adhesive layer 1210 can be roll coated onto a tabportion 1206 by a roller (not shown) that applies the adhesive to thetab portion whenever the tab portion is in contact with the roller. Theintermediate adhesive layer 1210 can be coated to a width between about0.5 and 2.0 inches, such as between about 0.75 and 1.5 inches, such asabout 1.0 inch. The intermediate adhesive layer 1210 can be applied to aheight between about 0.010 and 0.050 inches, such as between about 0.020and 0.040 inches, such as about 0.030 inches.

Referring to FIG. 36, granules 1211 are subsequently applied onto theintermediate adhesive layer 1210 to form the intermediate granulecoating 1211. The granules 1211 may optionally be pressed into theadhesive layer 1210, such that the granules become embedded in theadhesive layer 1210. The granules may be the same type of roofinggranules used at other parts of the shingle 1200. For example, thegranules may be the same type of granule used in the headlap portion ofthe shingle 1200.

Referring to FIG. 37, a first laminating adhesive 1216 is applied on theintermediate granule coating 1211 and a second laminating adhesive 3700is applied where an upper end 3800 of the underlay layer 1280 will bebonded to the overlay layer 1202. The second laminating 3700 adhesivecan take a wide variety of different forms. The second laminatingadhesive 3700 can be the same material as the first laminating adhesive1216 or a different material than the first laminating adhesive. Thesecond laminating adhesive 3700 and the first laminating adhesive 126can optionally be any of the materials that the intermediate adhesivelayer 1210 is made from. The intermediate adhesive 1210 can be the samematerial as the first laminating adhesive 1216 or a different materialthan the first laminating adhesive.

Referring to FIGS. 38 and 39, the underlay layer 1280 is then attachedto the overlay layer 1202 by the adhesives 1216, 3700 to form thelaminated shingle 1200. The overlay layer 1202 may be laminated to theunderlay layer 1280 in the conventional fashion with adhesives 1216,3700 and additional lines of adhesive or sealant. The deposited heightincreasing material 1209, formed of the intermediate adhesive layer 1210and intermediate granule coating 1211, under the headlap layer 1202increase the thickness of the shingle 1200 to create a thickened portion1212 at the front edges 3002 of the tab portions 1206. This gives theroof the appearance illustrated by FIG. 30.

FIGS. 40-44 illustrate an exemplary embodiment of a method for making ashingle where a height increasing material 1209 is deposited on thebottom surface 3100 of the underlay layer 1206 near the front edges 3002of the tab portions 1206 and near the cutout edge 1215 of the overlay1202. The intermediate adhesive layer 1210 near the front edges 3002extends only along the widths of the front edges of the tab portions1206 and the intermediate adhesive layer 1210 near the cutout edgesextends the entire width of the shingle 1200 (See FIG. 33). Theintermediate adhesive layers 1210 may be any adhesive known in the art.The intermediate adhesive layers 1210 can be roll coated onto a tabportion 1206 and a common bond area 4000 by one or more rollers (notshown). The one or more rollers can apply the adhesive to the tabportion whenever the tab portion is in contact with the roller and cancontinuously apply an intermediate adhesive layer to the common bondarea 4000. The intermediate adhesive layers 1210 can be coated to awidth between about 0.5 and 2.0 inches, such as between about 0.75 and1.5 inches, such as about 1.0 inch. The two illustrated intermediateadhesive layers can have the same width or different widths. Theintermediate adhesive layer 1210 can be applied to a height betweenabout 0.010 and 0.050 inches, such as between about 0.020 and 0.040inches, such as about 0.030 inches. The two illustrated intermediateadhesive layers can have the same height or different heights.

Referring to FIG. 41, granules 1211 are subsequently applied onto theintermediate adhesive layers 1210 to form the intermediate granulecoatings 1211. The granules 1211 may optionally be pressed into theadhesive layers 1210, such that the granules become embedded in theadhesive layers 1210. The granules may be the same type of roofinggranules used at other parts of the shingle 1200. For example, thegranules may be the same type of granule used in the headlap portion ofthe shingle 1200.

Referring to FIG. 42, laminating adhesives 1216 are applied on theintermediate granule coatings 1211. Referring to FIGS. 43 and 44, theunderlay layer 1280 is then attached to the overlay layer 1202 by theadhesives 1216 to form the laminated shingle 1200. The overlay layer1202 may be laminated to the underlay layer 1280 in the conventionalfashion with the adhesives 1216. The deposited height increasingmaterial 1209, formed of the intermediate adhesive layer 1210 andintermediate granule coating 1211, under the headlap layer 1202 increasethe thickness of the shingle 1200 to create a thickened portion 1212 atthe front edges 3002 of the tab portions 1206 and at the cutout edge1215.

FIGS. 45-49 illustrate an exemplary embodiment of a method for making ashingle where a height increasing material 1209 is deposited on thebottom surface 3100 of the underlay layer 1206 near the front edges 3002of the tab portions 1206, near the cutout edge 1215 of the overlay 1202,and between the front edges 3002 and the cutout edge. The intermediateadhesive layer 1210 near the front edges 3002 extends only along thewidths of the front edges of the tab portions 1206. The intermediateadhesive layer 1210 near the cutout edges 1215 extends the entire widthof the shingle 1200 (See FIG. 34). The intermediate adhesive layer 1210between the front edges 3002 and the cutout edges 1215 extends onlyalong the widths of the tab portions 1206. The intermediate adhesivelayers 1210 may be any adhesive known in the art. The intermediateadhesive layers 1210 can be roll coated onto a tab portion 1206 and thecommon bond area 4000 by one or more rollers (not shown). The one ormore rollers can apply the adhesive to the tab portion whenever the tabportion is in contact with the roller and can continuously apply anintermediate adhesive layer to the common bond area. The intermediateadhesive layers 1210 can be coated to a width between about 0.5 and 2.0inches, such as between about 0.75 and 1.5 inches, such as about 1.0inch. The three illustrated intermediate adhesive layers can have thesame width or different widths. The intermediate adhesive layer 1210 canbe applied to a height between about 0.010 and 0.050 inches, such asbetween about 0.020 and 0.040 inches, such as about 0.030 inches. Thethree illustrated intermediate adhesive layers can have the same heightor different heights.

Referring to FIG. 46, granules are subsequently applied onto theintermediate adhesive layers 1210 to form the intermediate granulecoatings 1211. The granules 1211 may optionally be pressed into theadhesive layers 1210, such that the granules become embedded in theadhesive layers 1210. The granules may be the same type of roofinggranules used at other parts of the shingle 1200. For example, thegranules may be the same type of granule used in the headlap portion ofthe shingle 1200.

Referring to FIG. 47, laminating adhesives 1216 are applied on theintermediate granule coatings 1211. The intermediate adhesive 1210 canbe the same material as the laminating adhesive 1216 or a differentmaterial than the laminating adhesive 1216.

Referring to FIGS. 48 and 49, the underlay layer 1280 is then attachedto the overlay layer 1202 by the adhesives 1216 to form the laminatedshingle 1200. The overlay layer 1202 may be laminated to the underlaylayer 1280 in the conventional fashion with the adhesives 1216. Thedeposited height increasing material 1209, formed of the intermediateadhesive layer 1210 and intermediate granule coating 1211, under theheadlap layer 1202 increase the thickness of the shingle 1200 to createa thickened portion 1212 at the front edges 3002 of the tab portions1206 and at the cutout edge 1215. A wide variety of different shingleconfigurations can be made in the general manner illustrated by theexamples of FIGS. 28-49.

FIG. 50 is a flowchart that illustrates an exemplary embodiment of amethod 5000 of making shingles 1200 with thickened portions 1209. In themethod, a substrate is coated 5010 with asphalt. The substrate can becoated with asphalt on the front and/or the back. The top of the asphaltcoated substrate is covered 5012 with granules. The bottom of theasphalt coated substrate is covered 5014. For example, the bottom of theasphalt coated substrate can be covered with sand, crushed rock,plastic, a stearate, a polymer, including, but not limited topolypropylene, or any other material that can keep stacked shingles fromsticking together. The substrate is cut 5016 into overlay and underlayportions. A thickening adhesive is applied 5018 to the bottom of theoverlay portion. Thickening granules are applied 5020 onto thethickening adhesive. The overlay portion is laminated 5022 to theunderlay portion. The laminated overlay and underlay portions are cutinto segments to form individual laminated shingles with thickenedportions 1209.

FIG. 51 is a flowchart that illustrates an exemplary embodiment of amethod 5100 of making shingles 1200 with thickened portions 1209. In themethod, a substrate is coated 5110 with asphalt. The substrate can becoated with asphalt on the front and/or the back. The top of the asphaltcoated substrate is covered 5112 with granules. The granules are pressed5113 into the asphalt coated substrate The bottom of the asphalt coatedsubstrate is covered 5114. For example, the bottom of the asphalt coatedsubstrate can be covered with sand, crushed rock, plastic, a stearate, apolymer, including, but not limited to polypropylene, or any othermaterial that can keep stacked shingles from sticking together. Whenbackdust, sand, crushed rock or other particulate material covers thebottom of the asphalt coated substrate, the particulate material ispressed 5115 into the asphalt coating. The substrate is cut 5116 intooverlay and underlay portions. A thickening adhesive is applied 5118 tothe bottom of the overlay portion. For example, the thickening adhesivecan be applied to the bottom of the overlay portion at the front of thetabs or dragon teeth, at the common bond area, and/or between the frontsof the dragon teeth and the common bond area. Thickening granules areapplied 5120 onto the thickening adhesive. The thickening granules arepressed 5121 are pressed into the thickening adhesive. Laminatingadhesive is applied 5122 to the thickening granules. The overlay portionis laminated 5123 to the underlay portion. The laminated overlay andunderlay portions are cut into segments to form individual laminatedshingles with thickened portions 1209.

Referring now to FIGS. 52-58, an exemplary folding shingle 5200 for useon a roof hip or ridge is shown. A front surface 5208 is shown in FIGS.52-56 and 58. A rear or back surface 5202 is shown facing upwards inFIG. 57. The shingle 5200 is shown in an unfolded condition in FIG. 52.The shingle 5200 has a folding portion 5201 and main body or unfoldedportion 5203. The folding portion 5201 is foldable along lines 5304,5305, 5306. The lines 5304, 5305, 5306 divide the folding portion 5201into three segments 5404, 5405, 5406. The fold lines 5304, 5305, 5306can take a wide variety of different forms that allow the segments 5404,5405, 5406 to be folded along the lines 5304, 5305, 5306. For example,the shingle 5200 can be perforated or scored along the fold lines.

The fold lines 5304, 5305, 5306 can optionally be reinforced to preventthe shingle 5200 from tearing along the fold lines 5304, 5305, 5306. Thereinforcement can be a reinforcing tape (See FIGS. 24-27). For example,a reinforcement tape can connect the segments 5404, 5405 together alongthe fold line 5304. This reinforcement tape can be provided on the topside of the shingle. A reinforcement tape can connect the segments 5405,5406 together along the fold line 5305. This reinforcement tape can beprovided on the bottom side of the shingle. A reinforcement tape canconnect the segment 5406 to the main body or unfolded portion 5203 alongthe fold line 5306. This reinforcement tape can be provided on thebottom side of the shingle.

In the illustrated embodiment, the three segments 5404, 5405, 5406include cutouts 5504, 5505, 5506 respectively. The cutouts 5504, 5505,5506 can take a wide variety of different forms. In the illustratedexample, the cutouts 5504, 5505, 5506 are circular in shape. However, inother embodiments, the cutouts 5404, 5505, 5506 can be ovals,rectangles, squares, diamonds, slits, etc. In the illustratedembodiment, each of the segments 5404, 5405, 5406 includes a singlecutout 5504, 5505, 5506. However, in other embodiments the segments5404, 5405, 5406 can have more than one cutout 5504, 5505, 5506 and thesegments 5404, 5405, 5406 can have different numbers of cutouts. In theillustrated example, the cutouts 5504, 5505, 5506 are aligned when thesegments 5404, 5405, 5406 are folded as shown in FIGS. 53-58. Thecutouts 5504, 5505, 5506 allow the stacked folded segments 5404, 5405,5406 to be bent over a hip or ridge of a roof. The shingle 5200 (as wellas any of the shingles disclosed herein) can be made from a polymermodified asphalt to further enhance the ability of the stacked foldedsegments 5404, 5405, 5406 to be bent of the hip or ridge of a roof. Awide variety of different polymer modified asphalt compositions can beused to make the shingles disclosed herein. In one exemplary embodiment,the polymer modified asphalt used to make the shingles disclosed hereinis a polymer modified asphalt composition disclosed by U.S. ProvisionalPatent Application Nos. 62/599,406 and 62/724,417, filed on Dec. 15,2017 and Aug. 29, 2018 respectively, which are incorporated herein byreference in their entirety.

FIGS. 53-58 illustrate folding of the shingle 5200 to form a hip orridge shingle having a thick front portion 5600 or “bull nose” (See FIG.56). Referring to FIG. 53, the segments 5404, 5405 are folded under thesegment 5406 and the unfolded portion 5203 fold line 5305. If included,a reinforcement tape along the fold line 5305 is sandwiched between theback surfaces of the segments 5405, 5406. As can be seen in FIG. 53, thecutouts 5505, 5506 become aligned or substantially aligned when thesegments 5405, 5406 are folded along the fold line 5305.

Referring to FIGS. 54-57, the segments 5405, 5406 are folded under thesegment 5404 and the unfolded portion 5203 along fold line 5306. Ifincluded, a reinforcement tape along the fold line 5304 is sandwichedbetween the front surfaces of the segments 5404, 5405. Referring to FIG.57, all three cutouts 5504, 5505, 5506 become aligned or substantiallyaligned when the segments 5405, 5406 are folded along the fold line5306. Referring to FIG. 56, the resulting folded shingle 5200 has afront end 5600 with four layers.

Referring to FIG. 58, the cutouts 5504, 5505, 5506 and/or the use ofpolymer modified asphalt to make the shingle 5200, allow the shingle tobe bent to match the shape of the roof ridge or hip.

The shingle 5200 may be attached to the roof 100 (FIG. 1) by anysuitable means, such as, for example, adhesive, nails, screws, staples,sealant, or other fastening devices. The bottom of the front end 5600(i.e. the top of segment 5406) optionally includes an adhesive portion5210 (See FIG. 56) arranged near the front end 5600 for adhering toshingles of an adjacent lower course after the shingle 5200 is foldedand installed.

The shingles 5200 can be fastened to the roof in a wide variety ofdifferent ways. Referring to FIG. 56, in one exemplary embodiment theshingles are attached to the roof with one or more fasteners through anail zone 5610. The nail zone 5610 can include a reinforcement tape5612. In another exemplary embodiment, the nail zone 5610 does notinclude a reinforcement tape and simply includes visual indicia thattells the installer where the shingle 5200 should be nailed to the roof.In the illustrated example, the nail zone 5610 is positioned rearward ofthe folded segments 5404, 5405, 5406, such that a fastener, such as anail, does not pass through the folded segments 5404, 5405, 5406. Inanother exemplary embodiment, the nail zone 5610 overlies the foldedsegments 5404, 5405, 5406, such that a fastener, such as a nail, passesthrough all four layers.

In one exemplary embodiment the shingle is folded to the configurationillustrated by FIG. 56, bent to the shape illustrated by FIG. 58, andfastened to the roof by nails or fasteners that are driven through thenail zone 5610. This folding, bending, placement, and fastening isrepeated for each overlying shingle. Each overlying shingle is placedsuch that the sealant or adhesive 5210 (FIG. 56) of the overlyingshingle aligns with the nail zone 5610 (FIG. 56) of the underlyingshingle.

In another exemplary embodiment, the shingle 5200 is installed in amanner that is the same, or similar to the installation illustrated byFIGS. 6-11. As with the roofing system illustrated by FIG. 6, theshingles 5200 can be used with an optional starter shingle 230. Thestarter shingle 230 may or may not include a folded portion to provide athicker appearance to a leading edge 5600. The leading edge 5600corresponds to the bottom portion of the shingle 5200 which is visibleby a person viewing the roof 100 from ground level.

FIGS. 7A-10A are similar to the example illustrated by FIGS. 7-10, butthe shingle 5200 is being installed. In this example, the second andthird segments 5405, 5406 or all three segments 5404, 5405, 5406 of afirst course of the folding shingle 5200 are nailed (or otherwisefastened) to the roof 100 with the main portion 5203 in an up-side downor unfolded condition. The nails 220 (or other fasteners) are appliedthrough one or more of the folded segments 5404, 5405, 5406 on oneside—the right side 112 in FIG. 7A—of the hip or ridge 104, 106. Thenails 220 are optionally only applied on one side so that the shingle200 can be folded along the fold line 5306. That is, if the shingle wasnailed on both sides it would be folded convexly over the hip or ridge104, 106, thereby making it difficult to fold the shingle along the foldline 5306 without tearing. The unfolded portion 5203 of the shingle 5200is folded up to meet the roof, thereby creating a thicker leading edge5212 and the exposed surface 208 faces outward, as shown in FIG. 8A. Theunfolded portion 5203 is in contact with the roof and can be optionallynailed down as well, on one or both sides 110, 112 of the hip or ridge104, 106.

The steps shown in FIGS. 7A and 8A are repeated with the second courseof folding shingles 5200, as shown in FIGS. 9A and 10A. The shingles ofthe second course, however, are nailed on the left side 110 of the hipor ridge 104, 106. The nails 220 in the second course penetrate thefirst course as well, thereby securing both sides of the first courseshingle. Shingles of additional courses are then applied in a similarmanner until the hip or ridge 104, 106 is covered in shingles 5200.During installation of additional courses, the nails 220 are applied toalternating sides 110, 112 of the hip or ridge 104, 106. The foldedportions 5404, 5405, 5406 of the shingles 5200 are folded under theunfolded portions 5203, thus providing the thicker appearance of theleading edge 5212 than would otherwise be provided by non-foldingshingles.

While various inventive aspects, concepts and features of thedisclosures may be described and illustrated herein as embodied incombination in the exemplary embodiments, these various aspects,concepts and features may be used in many alternative embodiments,either individually or in various combinations and sub-combinationsthereof. Unless expressly excluded herein all such combinations andsub-combinations are intended to be within the scope of the presentapplication. Still further, while various alternative embodiments as tothe various aspects, concepts and features of the disclosures—such asalternative materials, structures, configurations, methods, devices andcomponents, alternatives as to form, fit and function, and so on—may bedescribed herein, such descriptions are not intended to be a complete orexhaustive list of available alternative embodiments, whether presentlyknown or later developed. Those skilled in the art may readily adopt oneor more of the inventive aspects, concepts or features into additionalembodiments and uses within the scope of the present application even ifsuch embodiments are not expressly disclosed herein. Additionally, eventhough some features, concepts or aspects of the disclosures may bedescribed herein as being a preferred arrangement or method, suchdescription is not intended to suggest that such feature is required ornecessary unless expressly so stated. Still further, exemplary orrepresentative values and ranges may be included to assist inunderstanding the present application, however, such values and rangesare not to be construed in a limiting sense and are intended to becritical values or ranges only if so expressly stated. Moreover, whilevarious aspects, features and concepts may be expressly identifiedherein as being inventive or forming part of a disclosure, suchidentification is not intended to be exclusive, but rather there may beinventive aspects, concepts and features that are fully described hereinwithout being expressly identified as such or as part of a specificdisclosure, the disclosures instead being set forth in the appendedclaims. Descriptions of exemplary methods or processes are not limitedto inclusion of all steps as being required in all cases, nor is theorder that the steps are presented to be construed as required ornecessary unless expressly so stated. The words used in the claims havetheir full ordinary meanings and are not limited in any way by thedescription of the embodiments in the specification.

1. A roofing material comprising: an overlay layer having a headlapportion and a tab portion, wherein the headlap portion comprises abottom headlap edge and a top headlap edge; an underlay layer having aheight that extends from a bottom underlay edge to a top underlay edge,wherein the height of the underlay layer is less than a height of theoverlay layer; and an intermediate layer comprising a strip of materialthat increases a thickness of the roofing material, wherein theintermediate layer is positioned between the underlay layer and theoverlay layer such that the intermediate layer extends between the topunderlay edge and the bottom headlap edge.
 2. The roofing materialaccording to claim 1, wherein the intermediate layer is attached to theoverlay layer and the underlay layer by an adhesive.
 3. The roofingmaterial according to claim 2, wherein a height of the adhesive is lessthan a height of the strip of material of the intermediate layer.
 4. Theroofing material according to claim 1, wherein a top edge of theintermediate layer is colinear with the top underlay edge of theunderlay layer.
 5. The roofing material according to claim 1, wherein abottom edge of the intermediate layer is colinear with the bottomheadlap edge of the headlap portion of the overlay layer.
 6. The roofingmaterial according to claim 1, wherein the tab portion of the overlaylayer comprises a plurality of tabs that are defined by a bottom tabedge and a top tab edge, and wherein the top tab that is adjacent to thebottom headlap edge of the headlap portion.
 7. The roofing materialaccording to claim 1, wherein a width of the intermediate layer is equalto a width of the headlap portion of the overlay layer.
 8. The roofingmaterial according to claim 1, wherein a height extending from a bottomedge of the intermediate layer to a top edge of the intermediate layeris between 0.5 inches and 2 inches.
 9. The roofing material according toclaim 1, wherein the strip of material of the intermediate layercomprises a rectangular strip.
 10. The roofing material according toclaim 1, wherein the overlay layer comprises a reinforced nail zone, andwherein the intermediate layer extends under at least a portion of thereinforced nail zone.
 11. The roofing material according to claim 1,wherein the strip of material of the intermediate layer comprises aglass fiber mat.
 12. The roofing material according to claim 1, whereinthe strip of material of the intermediate layer comprises an organicfelt.
 13. The roofing material according to claim 1, wherein the stripof material of the intermediate layer has a uniform thickness.
 14. Theroofing material according to claim 1, wherein the overlay layercomprises an alignment guide to assist in aligning an adjacent roofingmaterial, and wherein a top edge of the intermediate layer is alignedwith the alignment guide.
 15. The roofing material according to claim 1,wherein the strip of material of the intermediate layer is separate fromthe overlay and underlay layers.
 16. The roofing material according toclaim 1, wherein the strip of material of the intermediate layer is afolded over portion of the underlay layer.
 17. The roofing materialaccording to claim 1, wherein a thickness of the strip of material ofthe intermediate layer is identical to the thickness of at least one ofthe overlay layer and the underlay layer.